I raised a recent topic about my Mk2 1.8 Focus over-revving. It looks like it’s caused by an air leak on the inlet side which requires the removal of the inlet manifold to investigate/fix.

Problem is, for the life of me I can’t find the outermost left/outermost right lower bolts. I got the rest, including the one that you reach from underneath, and the “most difficult” one between cyl 2 and 3.
 

I’ve seen a video of a 2.0 Duratec HE in a Mondeo being dismantled but as he says, it’s impossible to get a camera down there beforehand, and he only shows the manifold after it’s out so you can see where the bolt holes are. On mine there just doesn’t seem to be any access to them in situ. I can’t even see them with a torch and mirror.

As a side-issue, it doesn’t help that the bolt holes on mine are not all in a W pattern like his. For example, the upper/lower ones between cylinder 3&4 are vertically aligned on mine.

What am I missing, apart from a few grey cells?!

 

Have you tried checking an image of the part once removed e.g. from an ebay listing, to see exactly where the bolt holes are.

 

I've used that method before and found it really useful to better visualise where a bolt is (especially when I can't 'see' it whilst the part is still on the car).

My brother was told by a Ford main agent he would need a new manifold on his 2.0 cc.

Turned out to be a failed solenoid vacuum valve  , not sure if it was for the swirl flaps or egr. Easy and cheap repair in his case.

That’s a good idea, FatHead1979. Thanks.

Thanks RL123. I don’t know that the manifold does need replacing yet, but it has to come off anyway to expose the other potentially defective parts (eg split pipes, which seem to be the more likely candidates). 

P.S. What else would you expect from a main dealer?😉

Edited August 22, 20241 yr by rogerthebodger
Added a PS

The lower bolts should be right on the corners.  May need to do it by feel rather than sight.

2 hours ago, rogerthebodger said:

Thanks RL123. I don’t know that the manifold does need replacing yet, but it has to come off anyway to expose the other potentially defective parts (eg split pipes, which seem to be the more likely candidates). 

P.S. What else would you expect from a main dealer?😉

Based on years of being on this forum - I don't remember seeing may posts about ever needing to replace the actual inlet manifold on the 1.8/2.0 HE engine, it's usually the stuff inside/covered by the manifold such as the PCV bits etc.

 

Oh and i@m sure you're already aware but...more Ford stealers are...🐩💩

Thanks Tom, especially for the pic. That definitely looks more like my manifold. You’ve given me the will to go back out to the garage. 🙂👍🏻

Update: in spite of the assistance I got from this forum (for which I thank you) I eventually threw in the towel and got a mobile mechanic round. I quickly formed the opinion that he is an honest man (and trustworthy to boot).
 

Having got the manifold off, a split pipe was exposed (picture attached). It appears to be “double skinned”. Can someone please identify it and advise where I can get a replacement? I’ll get new inlet seals from there too. No surprise that Fords total price for these is £120!! I think I can do better…

It's been a few years since I had to mess with the inlet manifold and PCV system on my wife's old 1.8 Focus but isn't that the PCV hose? 

That's the PCV hose, also called an oil breather hose or oil separator hose.

Ford part number 1430644.  The genuine ones are over £50 from any retailer.  There are a few very cheap ones on ebay using that part number, though the quality and fit may be poor.  Or you can choose a silicone replacement here which should be more durable for around £30. Mondeo 2.0 Duratec Silicone PCV Crankcase Ventilation Hose 1430644 | eBay

Seals are 1119284.  Pack of 5 here for under £20. X5 Ford Focus Mondeo Fiesta Galaxy Transit Intake Manifold Gasket 1119284 OEM | eBay

And EGR seal here if that one needs replacing - Ford Fiesta ST150 Exhaust Gas Recirculation Gasket Ex Cosworth Stock | eBay

Apparently so, FH79 😉according to Tom👍🏻

Tom , why are there 5? In case one breaks? Also, the compatibility list for the breather hose doesn’t show a 1.8 Focus engine, it only lists the 2.0 size. Is it compatible with the 1.8 as well?

Good question...  I'd say it's more likely to replace one dropped into the engine bay and never to be seen again.  

The real reason is to do with the suppliers though.  It's not an 'engine pack' type thing.  Just the way they arrive at Ford dealers.  They're sold separately if you buy directly from Ford.  At a cost of £10 each! Genuine Ford Focus Mondeo Fiesta Galaxy Transit Intake Manifold Gasket 1119284 | eBay

The catalogues I have access to show the same hose for both 1.8 & 2.0 Duratec HE.  There's no harm in asking a seller to confirm compatibility before buying though.

15 minutes ago, rogerthebodger said:

Apparently so, FH79 😉according to Tom👍🏻

Tom , why are there 5? In case one breaks? Also, the compatibility list for the breather hose doesn’t show a 1.8 Focus engine, it only lists the 2.0 size. Is it compatible with the 1.8 as well?

The PCV valve and hose ARE the same on the MK2 Focus 1.8 and 2.0 petrol engines. (they're virtually the same engine)

Thank you, gentlemen👍🏻🙂